Compression molded trimmable surround

ABSTRACT

A trimmable surround and methods for creating the surround for a heat generating device. The trimmable surround includes a molded portion having a ceramic fiber and a binder and an attachment portion. A portion of the molded member is removable to alter a size of the molded member. An attachment portion coupled to the molded portion allows attachment of the trimmable surround to the heat generating device.

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims priority to U.S. Provisional patent applicationSer. No. 10/620,297 filed on Jul. 15, 2003 and entitled TRIMMABLESURROUND FOR A HEAT GENERATING DEVICE, which provisional application isincorporated herein by reference in its entirety.

TECHNICAL FIELD

The present invention relates to heat generating devices. Moreparticularly, the invention relates to a trimmable surround and a methodfor creating a modifyable surround for heat generating devices.

BACKGROUND

Fireplaces and other heat generating devices have become increasinglycommonplace in homes, businesses, and other buildings. For example, afireplace provides benefits including the generation of heat as well asan aesthetically-pleasing arrangement of flames, sounds, and smells. Afireplace is typically mounted in a wall of a structure and may includeone or more exposed surfaces.

The exposed surfaces of the fireplace can pose safety issues. Forexample, because the fireplace produces heat, it is possible for one ormore of the exposed surfaces of the fireplace to become heated. Inparticular, metallic exposed surfaces can become hot during fireplaceuse. Other surfaces of a fireplace that are typically exposed aresurfaces through which the interior of the fireplace is viewed (e.g., aglass panel, door, or mesh screen) and the surround that surrounds thefireplace and provides a transition between the exposed fireplacesurfaces and the wall structure.

The exposed surfaces of the surround may become hot and pose a risk ofburns to individuals or damage to objects that come into contact withthe surfaces. Current fireplace design fails to adequately provide anapparatus or method to maintain the exposed surfaces of the fireplacesurround at a temperature that is safe. Also, a metallic exposed surfaceof the fireplace may not be as aesthetically pleasing to the consumer orblend into a room's decor.

Further, surrounds are often required to cover gaps that may existbetween a combustion device, such as a fireplace insert, and theexisting structure of the building, such as a wall or masonry. Currentfireplace surrounds that are placed over the exposed surfaces of thefireplace can require custom measurement, cutting, and/or preparation bythe seller or manufacturer of the surround, are difficult to modify bythe consumer after purchase, and, if prepared with a finish prior toshipment to the consumer, may not match the decor surrounding thefireplace once placed over the exposed surface(s) of the fireplace unit.

SUMMARY

Generally, the present invention relates to heat generating devices.More particularly, the invention relates to a trimmable surround and amethod for creating a modifyable surround for heat generating devices.

According to one aspect, the invention relates to a trimmable surroundand methods for creating the surround for a heat generating device. Thetrimmable surround includes a molded portion having a ceramic fiber anda binder, and an attachment portion. The attachment portion is coupledto the molded portion to allow attachment of the trimmable surround tothe heat generating device. The trimmable surround may be reduced insize by, for example, cutting or trimming portions of the surround.

The above summary of the present invention is not intended to describeeach disclosed embodiment or every implementation of the presentinvention. Figures in the detailed description that follow moreparticularly exemplify embodiments of the invention. While certainembodiments will be illustrated and described, the invention is notlimited to use in such embodiments.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention may be more completely understood in consideration of thefollowing detailed description of various embodiments of the inventionin connection with the accompanying drawings, in which:

FIG. 1 is a front view of an example surround made in accordance withthe present invention;

FIG. 2 is a cross-sectional view taken along line 2-2 of the surroundshown in FIG. 1;

FIG. 3 is a front view of a second example surround made in accordancewith the present invention;

FIG. 4 is a back view of the surround shown in FIG. 3;

FIG. 5 is front/top exploded perspective view of the surround shown inFIG. 3;

FIG. 6 is a front view of an example fireplace including an exampleembodiment of a trimmable surround made in accordance with the presentinvention;

FIG. 7 is a front/top perspective view of the fireplace and trimmablesurround shown in FIG. 6;

FIG. 8 is a top view of the fireplace and trimmable surround shown inFIG. 6;

FIG. 8A is an enlarged view of a portion of the fireplace and trimmablesurround shown in FIG. 8;

FIG. 9 is a front/top exploded perspective view of the fireplace andtrimmable surround shown in FIG. 6;

FIG. 10 is a side view of the fireplace and trimmable surround shown inFIG. 6 installed within an opening of a wall structure; and

FIG. 10A is an enlarged view of a portion of the fireplace and trimmablesurround shown in FIG. 10.

While the invention is amenable to various modifications and alternativeforms, specifics thereof have been shown by way of example and thedrawings and will be described in detail. It should be understood,however, that the intention is not to limit the invention to theparticular embodiments described. On the contrary, the intention is tocover all modifications, equivalents, and alternatives falling withinthe spirit and scope of the invention.

DETAILED DESCRIPTION

The present invention relates to fireplaces. More particularly, theinvention relates to a surround for a fireplace that can be easilymodified, installed over or adjacent to an exposed surface of afireplace, and finished as desired by the consumer. While the presentinvention is not so limited, an appreciation of the various aspects ofthe invention will be gained through a discussion of the examplesprovided below.

Embodiments of the present invention may be used in conjunction with anysystem or apparatus that ignites a combustible gas to generate a gasflame or any other heat generating device. A non-exhaustive list of suchheat generating devices may include fireplaces, grills, stoves, furnacesetc. Other embodiments of the present invention may also be applicableto other heat generating devices such as electric fireplaces, and beapplicable to simulated fire display devices. While the exampleembodiments of the present invention provided below are described inconjunction with an example fireplace insert, the present invention isequally applicable to other systems or apparatuses besides a fireplacethat ignite a combustible gas to generate a gas flame or that simulate aflame.

As used herein, the term “coupled” means any structure or method thatmay be used to provide connectivity between two or more elements, whichmay or may not include a direct physical connection between theelements. The terms “exposed panel” and “exposed surface” mean any panelor surface of the fireplace or other device that may heated by heatgenerated by the fireplace and that is accessible by the operator oruser of the fireplace following installation. The phrase “combustionchamber enclosure” may include any enclosure in which flames and/or heatare generated or simulated. The term “surround” means any exposedstructural surface that covers or is adjacent to a portion of thefireplace (e.g., “exposed surface”) or structure adjacent thereto.

Referring to FIGS. 1 and 2, front and cross-sectional views of anexample embodiment of a trimmable surround 100 are shown. The trimmablesurround 100 may be comprised of any material that provides a surface102 that insulates a user of a fireplace from at least one exposedsurface of the fireplace. The trimmable surround 100 includes a moldedportion 104 that includes a top portion 106, and two side portions 108,110.

Molded portion 104 can be formed from, for example, inorganic ceramicfibers and a binder. Molded portion 104 can be formed by any knownmolding technique, such as, for example, compression molding, vacuumforming, or casting techniques. Exemplary molding compositions andforming techniques are described in pending United States PublicationNo. US-2003-0049575-A1, which is incorporated herein by reference in itsentirety. Additional exemplary molding compositions and formingtechniques are described in U.S. Pat. Nos. 5,941,237; 5,996,575; and6,170,481, which patents are incorporated herein by reference in theirentirety.

The top portion 106 and two side portions 108, 110 can define an opening111 that typically corresponds to the dimensions of a glass panel thatallows viewing into the fireplace. For example, opening 111 isapproximately 34 inches wide along dimension W and 26 inches high alongdimension X. These dimensions can correspond to the opening of a numberof gas fireplace inserts. For example, the dimensions of opening 111 canbe used with a Hearth & Home Technologies (Lakeville, Minn.) fireplaceinsert sold under the names of FB-GRAND. The side portions 108, 110 oftrimmable surround 100 can have a width Y of about, for example, 3-10inches and preferably has a width of about 7 inches. The top portion 106can have a dimension Z of about, for example, 3-10 inches and preferablyhas a width Z of about 6 inches. Trimmable surround 100 can be formed inany other desired size, shape and configuration to the configurationshown in the Figures. For example, trimmable surround can be formed andsized to cover exposed surfaces of wood stoves or other combustiondevices.

Surround 100 can be attached to a combustion device using, for example,screws, bolts, or high temperature adhesives, and may further requireplacing the surround in front of the combustion device, sizing thesurround to press fit into an opening, or utilizing other attachmentdevices, such as the apparatus disclosed in FIGS. 3-5.

Referring to FIGS. 3-5, another embodiment of a trimmable surround 200is shown. The trimmable surround 200 includes a molded portion 204having a top portion 206, and two side portions 208, 210. The topportion 206 and two side portions 208, 210 can define an opening 211having dimensions A, B (see FIG. 4), which dimensions may be similar todimensions Y, Z for surround 100.

Trimmable surround 200 also includes an attachment portion 212. Theattachment portion 212 includes a right bracket 214, left bracket 216,and a top bracket 218. Optionally included is a bottom bracket 217.Although shown a multiple parts, alternatively, attachment portion canbe constructed as a single unit. Flanges 220, 221 extend from a bottomportion 222 of each of the right and left brackets 214, 216.

Top bracket 218 includes air holes 224, 225, 226, 227 that allow for thecirculation of heated room air. Air holes 224, 225, 226, 227 are onlyone example of a construction that will allow for the return of air intothe room in which a fireplace is located. Alternatively, a single airhole can be used, or if no circulation of room air is desired, the airholes can be eliminated.

As shown in FIG. 4, the attachment portion 212 can be screwed into aback surface 228 of the molded portion 204. Alternatively, attachmentportion 212 can be coupled to the molded portion through other means,such as, for example, bolting, adhering, or forming the attachmentportion into the molded portion during the molding process. Theattachment portion 212 allows an installer to couple the molded portion204 to a combustion device.

Trimmable surrounds 100, 200 can be manipulated in any number of ways.In one method, a standard size surround is used and can be trimmed bythe consumer as desired. The consumer purchases the trimmable surround,such as surrounds 100, 200, with the intention of trimming the surroundto a size that fits a particular fireplace opening or exposed surfacethat is to be at least partially covered with a finished surround.

A consumer can trim a surround to a desired size according to thefollowing example steps. After purchasing a trimmable surround (such as100, 200) of a desired size, shape, or dimension, the consumer canutilize a template, which is either supplied by the manufacturer orcreated by the consumer, to trace a combustion device opening in which acombustion device is disposed. After tracing the combustion deviceopening, the consumer cuts the template and verifies that the finishedtemplate fits within the combustion device opening. In some embodiments,the template may be cut to a size larger or smaller than the combustiondevice opening so that the trimmed surround properly overlaps or residesadjacent to the combustion device opening as desired.

Once a final template is created, the inside opening of the template isaligned with an opening (111, 211) of the trimmable surround (100, 200)on a front surface of the trimmable surround (100, 200). The consumerthen traces around the template to mark off the size of the combustiondevice opening. The consumer next cuts or removes the excess portions ofthe trimmable surround (100, 200) off using a jig saw, skill saw, handsaw or other cutting device. Cutting may be done along, for example,inner edges 203, 205 of the side portions 208, 210, or cutting maydefine the edges 203, 205. The consumer can leave the template in placeon the front surface (103, 203) of the trimmable surround (100, 200)during the cutting process. Alternatively, the template can be removedprior to cutting the trimmable surround (100, 200). In furtherembodiments, the surround may be constructed so that the sizemodifications to the surround can be made by breaking, bending, orotherwise removing predetermined sections, strips, or other pieces fromthe surround.

After cutting the trimmable surround (100, 200), the consumer can paintor stain the outer surface facing (e.g., surface 102) of the surround tomatch the surrounding decor of the room or fireplace structure. Staininga compression molded fiber material may provide a marbleized or otherspecific look to the trimmable surround depending on the fiber materialand method of molding. After preparing the finish on the trimmablesurround (100, 200), the surround can be installed onto the fireplace,insert, stove, or other heat generating device.

Trimmable surround can also be manipulated in other ways. For example,patterns, designs, initials, or other decorative modifications can bemade to the trimmable surround (100, 200) prior to or after installationin the fireplace opening. Functional modifications can also be made. Forexample, holes or openings can be created in the trimmable surround(100, 200) to allow for air passage around the fireplace. These types ofmodifications can be made to the surround before or after the surroundis installed depending of the type of modification being made.

Referring to FIGS. 6-9, trimmable surround 200 is shown coupled to acombustion device 250 (heat generating device), such as a fireplaceinsert. Combustion device 250 is illustrated including an outerenclosure 252 having a front panel 254, top panel 256, back panel 258,and two side panels 260, 262.

Coupling of the trimmable surround 200 to front panel 254 can covergaps, such as gap R shown in FIG. 10, between an existing structure 264,such as a wall or masonry, and the combustion device 250 being covered.As shown in FIG. 10, the trimmable surround 200 can been sized to fitwithin an opening 279 in a wall 265 of the existing structure 264. Forexample, if a height of the trimmable surround 200 is too tall to fitwithin the opening of the wall 265, an upper portion 281 of the surround200 can be trimmed to lower the surround and allow the surround to fitwithin the opening 279 in the wall 265. Likewise, side portions 208, 210can be trimmed on outer side edges 207, 209 (see FIG. 9) as necessary toconform to the opening in a wall 265, or can be trimmed on inner edges203, 205 (see FIG. 5) to properly cover the exposed surface 251 of thecombustion device 250. Similar modifications can be made to the topportion 106 and side portions 108, 110 of trimmable surround 100.

The combustion device 250 may generally function to ignite combustiblegas provided from a combustible gas source to create a gas flame. Forexample, a burner (not shown) can be positioned within the combustiondevice 250, which generates heat that increases the temperature of anexposed surface and the outer enclosure 252. Often, when a surround isformed of a metal material, the exposed surface is heated to atemperature that can cause injury to an individual who touches thesurface unless all or a portion of the exposed surface is isolated fromthe heat to lower the temperature of the exposed surface.

As shown in FIGS. 6-10, utilization of trimmable surround 200 provides abarrier between the user of the combustion device 250 and the exposedsurface 251 (see FIG. 9), and minimizes the amount of the exposedsurface 251. This type of barrier may be particularly relevant whensurface 251 includes a metal or other high heat conductive material.Trimmable surround 200 may be composed of a ceramic fiber and a binder,which is a non-metallic material. Another exemplary non-metallicmaterial for surround 200 is fiberglass. In prior surround systems,metal is primarily used as the material for covering gaps between thecombustion device 250 and the existing wall or masonry of a structure.

Room air may be heated as it travels around the outer enclosure 252.Optionally, a blower (not shown) can be used for moving room air intoand out of an area surrounding the combustion device 250. An exhaust 266exhausts combusted air from the combustion device 250. The combustiondevice 250 may also include an air intake 268 that facilitates bringingfresh combustion air into the combustion device 250 for combustion.

Screws, bolts, high temperature adhesives, or other attachment devicescan be utilized to attach the trimmable surround 200 to the combustiondevice 250. For example, the trimmable surround 200 may be coupled todevice 250 with mounting screws that pass through flanges 220, 221 andinto lower portions 269, 270 of the combustion device 250. As shown bestin FIGS. 8A and 10A, the top bracket 218 can include slots 271 thatreceive mounting tabs 273 of the combustion device 250.

FIGS. 6-10 show a combustion device in one configuration. Otherconfigurations are also possible. For example, the present invention maybe applicable to any prefabricated gas fireplace such as a direct vent,a universal vent, a B-vent, a horizontal/vertical-vent, a dual directvent, or a multisided unit. For a multi-sided fireplace such as the onedisclosed in U.S. Pat. No. 5,016,609, incorporated herein by referencein its entirety, a single surround formed from a single molded piece,can be placed over the multiple exposed sides of the multi-sided unit.Alternatively, a multiple number of panels can be placed over eachexposed side of the multi-sided fireplace unit. The present inventionmay also be applicable to free standing wood stoves and wood inserts.

The present invention may also be applicable to other combustible gasfireplace systems, as noted above, as well as any other fireplace ordevice that generates heat such as a simulated electric fireplace orsolid fuel-burning fireplace. For example, the simulated electricfireplace may be constructed within the outer enclosure 252. Thesimulated electric fireplace can include several electrical componentssuch as a simulated ember bed, lights, a heat source, and a blower.

As previously noted, the present invention is applicable for use withfireplaces of varying sizes and shapes. The surround can be trimmed andmodified as needed to fit a given fireplace configuration. For example,if a fireplace includes an arch-shaped front panel, an upper portion ofthe opening of the surround can be cut to conform to the arch-shapedfront panel. If such a fireplace is used, one or more pieces of theattachment portion, such as the top bracket, can be removed if necessaryand only the right and left brackets used to couple the surround to thefireplace.

The example surrounds disclosed herein can be used to finish a newfireplace installation or to refinish a fireplace that has beenpreviously installed. For example, existing fireplaces that includemetallic surrounds can be refinished using surrounds 100, 200 disclosedherein. If an existing metallic surround is to be replaced, the metallicsurrounds can be removed prior to installation of the new surround, orthe new surround can simply be placed over the existing metallicsurrounds.

The present invention should not be considered limited to the particularexamples or materials described above, but rather should be understoodto cover all aspect of the invention as fairly set out in the attachedclaims. Various modifications, equivalent processes, as well as numerousstructures to which the present invention may be applicable will bereadily apparent to those of skill in the art to which the presentinvention is directed upon review of the instant specification.

1. A trimmable surround for a heat generating device, the trimmablesurround comprising: a molded member comprising a ceramic fiber and abinder, a portion of the molded member being removable to alter a sizeof the molded member; and an attachment member coupled to the moldedmember and configured to couple the trimmable surround adjacent to anexposed panel of the heat generating device.
 2. The trimmable surroundof claim 1, wherein the attachment member comprises a top bracket, thetop bracket defining a slot configured to receive a mounting tab of theheat generating device.
 3. The trimmable surround of claim 1, whereinthe heat generating device is a fireplace insert.
 4. The trimmablesurround of claim 1, wherein the molded member comprises a top memberand opposing side members.
 5. The trimmable surround of claim 1, whereinthe size of the molded member to be altered is a height or a width ofthe surround outer circumference.
 6. The trimmable surround of claim 1,wherein the size of the molded member to be altered is a height or awidth of an inner opening sized to cover at least a portion of theexposed panel.
 7. The trimmable surround of claim 1, wherein the moldedmember comprises an outer surface configured for forming a decorativedesign.
 8. The trimmable surround of claim 1, wherein the molded memberis formed by compression molding.
 9. A gas fireplace comprising: a frontpanel including an exposed portion; a surround positioned adjacent tothe front panel, the surround comprising: a molded member comprising aceramic fiber and a binder, a portion of the molded member beingremovable to alter a size of the molded member; and an attachment membercoupled to the molded member, the attachment member being configured tosecure the surround adjacent to the front panel; wherein the front panelis positioned to cover at least a portion of the exposed surface of thefront panel.
 10. The fireplace of claim 9, wherein the attachment memberis configured to secure the surround to the front panel.
 11. Thefireplace of claim 9, wherein the molded member defines an opening, anda portion of the molded member adjacent the opening covers at least aportion of the exposed portion of the front panel.
 12. The fireplace ofclaim 11, wherein the portion of the molded member that is removablealters a size of the opening of the molded member.
 13. The fireplace ofclaim 9, wherein the size of the molded member to be altered is a heightor a width of the surround outer circumference.
 14. A method of sizing asurround for a heat generating device, the method comprising the stepsof: providing a trimmable surround sized greater than an opening definedby the heat generating device, the trimmable surround comprising: amolded portion, the molded portion comprising a ceramic fiber and abinder; and an attachment portion coupled to the molded portion, theattachment portion being configured to attach the trimmable surround ina position in front of an exposed panel of the heat generating device;measuring a size of the heat generating device opening; and removing aportion of the trimmable surround based on the measured size of the heatgenerating device opening.
 15. The method of claim 14, furthercomprising the step of attaching the trimmable surround to the heatgenerating device.
 16. The method of claim 14, further comprising thestep of preparing a template based upon the measured size of the heatgenerating device opening.
 17. The method of claim 16, furthercomprising the step of placing the template on the trimmable surround,wherein the step of removing a portion of the trimmable surroundincludes sizing a dimension of the surround to approximate a dimensionof the template.
 18. The method of claim 14, wherein removing a portionof the trimmable surround alters an outer circumference dimension of thesurround.
 19. The method of claim 14, wherein removing a portion of thetrimmable surround alters a size of an opening defined by the moldedportion, the opening having dimensions that approximate the measuredsize of the heat generating device opening.
 20. The method of claim 14,wherein the step of removing a portion of the trimmable surroundincludes cutting the molded portion.
 21. The method of claim 14, furthercomprising forming the molded member by compression molding.
 22. Themethod of claim 14, further comprising forming the molded member byvacuum molding.
 23. The method of claim 14, further comprising formingthe molded member by casting.